JP2006035507A - Flexible, nonflammable decorative plate - Google Patents
Flexible, nonflammable decorative plate Download PDFInfo
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Abstract
Description
本発明は、可撓性不燃化粧板に関する。 The present invention relates to a flexible incombustible decorative board.
従来、厚み数センチの化粧ボードを曲げ加工用途に用いる場合、裏面に溝を切削する方法が知られている。 Conventionally, when a decorative board having a thickness of several centimeters is used for bending, a method of cutting a groove on the back surface is known.
しかしながら、化粧ボードの裏面より溝を入れた場合、曲げ加工により化粧ボードが破損することがあった。 However, when a groove is formed from the back side of the decorative board, the decorative board may be damaged by bending.
本発明は、かかる状況に鑑み検討されたもので、不燃性能を有し、かつ曲げ加工に優れる化粧板を得ることを目的とするもので、以下のことを特徴とする。
すなわち、請求項１記載の発明は、軟質難燃コア層と、金属箔と、表面化粧層とを順次積層し、一体成型してなることを特徴とする可撓性不燃化粧板である。
請求項２記載の発明は、該軟質難燃コア層が、繊維基材に熱可塑性樹脂と無機充填剤とからなるスラリーが含浸された樹脂含浸プリプレグからなることを特徴とする可撓性不燃化粧板である。
請求項３記載の発明は、該熱可塑性樹脂と該無機充填剤の配合割合が固形分比で１：３〜１：１０であることを特徴とする請求項２記載の可撓性不燃化粧板である。
請求項４記載の発明は、該スラリーの含浸率が数１で示される算出方法で７００〜２０００％であることを特徴とする請求項２記載の可撓性不燃化粧板である。
請求項５記載の発明は、該熱可塑性樹脂のガラス転移温度（Ｔｇ）が０℃以下であることを特徴とする請求項２又は３記載の可撓性不燃化粧板である。
請求項６記載の発明は、該熱可塑性樹脂がアクリル樹脂又はＳＢＲラテックスであることを特徴とする請求項２、３又は５記載の可撓性不燃化粧板である。
請求項７記載の発明は、該表面化粧層がメラミン樹脂含浸化粧紙であることを特徴とする請求項１記載の可撓性不燃化粧板である。
The present invention has been studied in view of such circumstances, and an object of the present invention is to obtain a decorative board having nonflammability and excellent bending work, and is characterized by the following.
That is, the invention described in claim 1 is a flexible non-combustible decorative board comprising a soft flame-retardant core layer, a metal foil, and a surface decorative layer that are sequentially laminated and integrally molded.
The invention according to claim 2 is characterized in that the soft flame-retardant core layer is made of a resin-impregnated prepreg in which a fiber base material is impregnated with a slurry made of a thermoplastic resin and an inorganic filler. It is a board.
The invention according to claim 3 is characterized in that the blending ratio of the thermoplastic resin and the inorganic filler is 1: 3 to 1:10 in solid content ratio. It is.
The invention according to claim 4 is the flexible non-combustible decorative board according to claim 2, wherein the impregnation ratio of the slurry is 700 to 2000% by the calculation method represented by Equation 1.
The invention according to claim 5 is the flexible noncombustible decorative board according to claim 2 or 3, wherein the thermoplastic resin has a glass transition temperature (Tg) of 0 ° C or lower.
The invention according to claim 6 is the flexible non-combustible decorative board according to claim 2, 3 or 5, wherein the thermoplastic resin is an acrylic resin or SBR latex.
The invention described in claim 7 is the flexible non-combustible decorative board according to claim 1, wherein the surface decorative layer is a decorative paper impregnated with melamine resin.
本発明によれば、耐衝撃性、強度に優れる上、フレキシビリティであり、水打ちや熱加工等の特殊な処理無しでかつ常温において曲面用途に用いることができ、裏面側に溝を形成する必要がない。
以下、本発明について詳細に説明する。
According to the present invention, it has excellent impact resistance and strength, is flexible, can be used for curved surfaces at room temperature without special treatment such as water hammering and thermal processing, and has a groove on the back side. There is no need.
Hereinafter, the present invention will be described in detail.
本発明の軟質難燃コア層は、酢酸ビニル樹脂、ＳＢＲ、アクリル樹脂、スチレンアクリル樹脂などの熱可塑性樹脂と無機充填剤などからなるスラリーを、無機繊維基材や有機繊維基材などの繊維基材に含浸したものである。
無機繊維基材としては、ガラス繊維、ロックウール、炭素繊維などの無機繊維からなる不織布、織布などが挙げられる。無機繊維基材の坪量は、１０〜２００ｇ／ｍ２の範囲が好適であり、とりわけ、耐熱性、耐炎性に優れ、スラリーの含浸性が優れるガラス繊維不織布を用いるのが好ましい。
有機繊維としては、例えばポリエチレン、ポリプロピレン、ビニロン、ポリ塩化ビニル、ポリ塩化ビニリデン、ポリアクリロニトリル、ポリアミド、ポリエステル、ポリウレタン等やこれらの変成物およびエチレン−酢酸ビニル共重合体などに代表される各種共重合体からなる繊維およびこれらの混合物か、さらにはこれらの重合体からなる複合繊維などが挙げられる。
熱可塑性樹脂の中でも曲げ性、密着性、成形性に優れるガラス転移温度が０℃以下のアクリル樹脂又はＳＢＲラテックスが好ましく、有機繊維の中では引っ張り強度の優れるポリエステルが好ましい。
The soft flame retardant core layer of the present invention comprises a slurry composed of a thermoplastic resin such as vinyl acetate resin, SBR, acrylic resin, styrene acrylic resin and an inorganic filler, and a fiber base such as an inorganic fiber base material or an organic fiber base material. The material is impregnated.
Examples of the inorganic fiber substrate include nonwoven fabrics and woven fabrics made of inorganic fibers such as glass fibers, rock wool, and carbon fibers. The basis weight of the inorganic fiber substrate is preferably in the range of 10 to 200 g / m 2 , and it is particularly preferable to use a glass fiber nonwoven fabric that is excellent in heat resistance and flame resistance and excellent in impregnation of slurry.
Examples of organic fibers include polyethylene, polypropylene, vinylon, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyamide, polyester, polyurethane, etc. and their modified products and various copolymers represented by ethylene-vinyl acetate copolymer. Examples thereof include fibers made of coalescence and a mixture thereof, and composite fibers made of these polymers.
Among thermoplastic resins, an acrylic resin or SBR latex having a glass transition temperature of 0 ° C. or less that is excellent in bendability, adhesion, and moldability is preferable, and polyester having excellent tensile strength is preferable among organic fibers.
スラリー中に含まれる無機充填剤は成形性の安定化、強度の向上、及び難燃効果を目的とするものであり、具体的には、水酸化アルミニウム、水酸化マグネシウム、炭酸カルシウム、シリカなどが挙げられ、平均粒子径が０．５〜２００μｍの範囲のものが繊維基材への含浸が可能であり、中でも、水酸化アルミニウムや水酸化マグネシウムなど結晶水を含むものは耐水性、耐熱性に優れる。 The inorganic filler contained in the slurry is for the purpose of stabilizing moldability, improving strength, and flame retardancy, and specifically includes aluminum hydroxide, magnesium hydroxide, calcium carbonate, silica and the like. Those having an average particle size in the range of 0.5 to 200 μm can be impregnated into the fiber base material. Among them, those containing crystal water such as aluminum hydroxide and magnesium hydroxide are water resistant and heat resistant. Excellent.
該スラリー中の熱可塑性樹脂分と無機充填剤との配合割合は固形分比で１：３〜１：１０の範囲とするのが望ましく、熱可塑性樹脂分に対して無機充填剤が多いと密着性が低下し、また、無機充填剤が少くなると熱圧成形時に樹脂が染み出したりする。 The blending ratio of the thermoplastic resin and the inorganic filler in the slurry is preferably in the range of 1: 3 to 1:10 in terms of solid content, and if the inorganic filler is more than the thermoplastic resin, the slurry is in close contact. If the inorganic filler is reduced, the resin may ooze out during hot pressing.
繊維基材へのスラリー固形分含有率（％）は、数１で示される算出方法で、７００〜２０００％の範囲が好ましい。上限を超えると固形分の脱落が多くなり取り扱いにくく、また下限に満たないと層間剥離しやすくなる。
スラリー中に含まれる無機充填剤としては、水酸化アルミニウム、水酸化マグネシウム、炭酸カルシウム、シリカなどが挙げられ、平均粒子径が０．５〜５００μｍの範囲のものが無機性繊維不織布への含浸が可能であり、中でも、水酸化アルミニウムや水酸化マグネシウムなど結晶水を含むものは高温時に分解し、吸熱、結合水を放出するため不燃性の効果の点で最適である。 Examples of the inorganic filler contained in the slurry include aluminum hydroxide, magnesium hydroxide, calcium carbonate, silica, and the like, and those having an average particle size in the range of 0.5 to 500 μm impregnate the inorganic fiber nonwoven fabric. Among them, those containing crystal water such as aluminum hydroxide and magnesium hydroxide are optimal in terms of nonflammability because they decompose at high temperatures and release heat and bound water.
有機樹脂分と無機充填剤との配合割合は５〜２０：９５〜８０とするのが望ましく、有機樹脂分に対して無機充填剤が多くなると不燃性能が向上するものの密着性が低下し、また、無機充填剤が少くなると密着性が向上するものの不燃性能が低下する。 The blending ratio of the organic resin component and the inorganic filler is desirably 5 to 20:95 to 80. If the amount of the inorganic filler is increased with respect to the organic resin component, the nonflammability is improved, but the adhesion is decreased. When the inorganic filler is decreased, the incombustibility is lowered although the adhesion is improved.
金属箔の材質としては、鉄、銅、アルミニウム、ステンレスなどが挙げられ、プリプレグ、化粧層との密着性を向上させるため接着紙、例えば、フェノールブチラールが含浸塗布されたものが用いられる。中でも熱分解温度が高く耐熱性に優れる銅箔が好ましく、厚さは常温での曲げ加工性を考慮すると１〜１００μｍが望ましい。アルミニウム箔の場合、厚みが薄いと分解して不燃性が低下するため３０μｍ以上が好ましい。
金属箔を用いることにより、熱拡散効果とガスバリア効果が発揮され、また、裏面に溝を切削する必要もなく、破損しにくいといった補強効果がある。
Examples of the material of the metal foil include iron, copper, aluminum, and stainless steel. Adhesive paper such as phenol butyral is impregnated and applied to improve adhesion to the prepreg and the decorative layer. Among them, a copper foil having a high thermal decomposition temperature and excellent heat resistance is preferable, and the thickness is preferably 1 to 100 μm in consideration of bending workability at room temperature. In the case of an aluminum foil, the thickness is preferably 30 μm or more because the aluminum foil decomposes and the nonflammability decreases when the thickness is small.
By using the metal foil, a thermal diffusion effect and a gas barrier effect are exhibited, and there is no need to cut a groove on the back surface, and there is a reinforcing effect that it is difficult to break.
金属箔の上には、表面化粧層として熱硬化性樹脂含浸化粧紙が積層される。熱硬化性樹脂含浸化粧紙は、６０〜１８０ｇ／ｍ２の化粧板用化粧紙に、アミノ−ホルムアルデヒド樹脂、ジアリルフタレート樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂からなる樹脂液を数２で示される含浸率が８０〜２００％となるように含浸し、乾燥したものである。
とりわけメラミン−ホルムアルデヒド樹脂を用いるのが硬度、耐汚染性の面から好ましい。
In particular, it is preferable to use a melamine-formaldehyde resin in terms of hardness and stain resistance.
アミノ−ホルムアルデヒド樹脂としてはアミノ化合物、例えばメラミン、尿素、ベンゾグアナミン、アセトグアナミンなどとホルムアルデヒドを反応させた初期縮合物のほか、メチルアルコール、ブチルアルコールなどの低級アルコ−ルによるエ−テル化、パラトルエンスルホンアミドなどの可塑化を促す反応性変性剤で変性されたものが適用でき、中でも耐久性に優れるメラミン−ホルムアルデヒド樹脂が好ましい。 Amino-formaldehyde resins include amino compounds such as melamine, urea, benzoguanamine, acetoguanamine, etc., initial condensation products obtained by reacting formaldehyde, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluene. Those modified with a reactive modifier that promotes plasticization such as sulfonamide can be applied, and among them, a melamine-formaldehyde resin excellent in durability is preferable.
プリプレグと、金属箔と、熱硬化性樹脂含浸化粧紙とは積層された後、平板プレス、連続プレスなどのプレス機で熱圧一体化される。
積層する際には、最下層に反りを抑制するためバランス紙を配してもよく、バランス紙としては、前記の熱硬化性樹脂含浸表面紙の他、クラフト紙に、フェノール樹脂、アミノ−ホルムアルデヒド樹脂、ジアリルフタレート樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂からなる樹脂液を含浸した熱硬化性樹脂含浸クラフト紙などが挙げられる。
After the prepreg, the metal foil, and the thermosetting resin-impregnated decorative paper are laminated, they are hot-pressure integrated by a press machine such as a flat plate press or a continuous press.
When laminating, a balance paper may be arranged in the lowermost layer to suppress warpage. As the balance paper, in addition to the above thermosetting resin-impregnated surface paper, kraft paper, phenol resin, amino-formaldehyde Examples thereof include thermosetting resin-impregnated kraft paper impregnated with a resin liquid composed of a thermosetting resin such as resin, diallyl phthalate resin, and unsaturated polyester resin.
以下、実施例を挙げてより詳細に説明するが、本発明をより具体的に示すものであって、特に限定するものではない。
実施例１
軟質難燃コア層
７０ｇ／ｍ２のポリエステル繊維不織布に、Ｔｇが−５０℃のアクリル樹脂１２部に対して、水酸化アルミニウムを８８部配合したスラリーを、式１に示すスラリー固形分定着率が９００％となるように含浸してプリプレグ（ａ）を得た。
熱硬化性樹脂含浸化粧紙
坪量８０ｇ／ｍ２の化粧板用化粧紙にメラミン−ホルムアルデヒド樹脂からなる樹脂液を含浸して熱硬化性樹脂含浸化粧紙を得た。
可撓性不燃化粧板
プリプレグ（ａ）を６枚、片面接着処理された厚み３５μｍの銅箔１枚と、熱硬化性樹脂含浸化粧紙を１枚、接着処理面が含浸化粧紙に当接するように積層し、１３０℃，７０ｋｇ／ｃｍ２、９０分間の条件で熱圧成形し、実施例１の可撓性不燃化粧板を得た。
EXAMPLES Hereinafter, although an Example is given and demonstrated in detail, this invention is shown more concretely and is not specifically limited.
Example 1
Soft flame retardant core layer A slurry in which 88 parts of aluminum hydroxide is blended with 12 parts of acrylic resin having a Tg of −50 ° C. in a polyester fiber nonwoven fabric of 70 g / m 2 has a slurry solid content fixing ratio shown in Formula 1. A prepreg (a) was obtained by impregnation so as to be 900%.
Thermosetting resin-impregnated decorative paper A decorative paper for decorative plates having a basis weight of 80 g / m 2 was impregnated with a resin solution comprising a melamine-formaldehyde resin to obtain a thermosetting resin-impregnated decorative paper.
Flexible non-combustible decorative board 6 sheets of prepreg (a), 1 sheet of copper foil with a thickness of 35 μm bonded on one side, 1 sheet of thermosetting resin-impregnated decorative paper, and the adhesive-treated surface abuts on the impregnated decorative paper And subjected to hot pressing under conditions of 130 ° C. and 70 kg / cm 2 for 90 minutes to obtain a flexible noncombustible decorative board of Example 1.
実施例２
実施例１において銅箔の代わりに厚さ５０μｍのアルミ箔を用いた以外は同様に実施した。
Example 2
In Example 1, it implemented similarly except having used the 50-micrometer-thick aluminum foil instead of copper foil.
実施例３
実施例１において、銅箔の直下に２８ｇ／ｍ２の化粧含用の原紙にフェノール−ブチラールを含浸塗布した接着紙を挿入して積層した以外は同様に実施した。
Example 3
In Example 1, it carried out similarly except having inserted and laminated | stacked the adhesive paper which impregnated and apply | coated the phenol-butyral to the base paper for cosmetics containing 28 g / m <2> directly under copper foil.
比較例１
実施例１において、銅箔を用いなかった以外は同様に実施した。
Comparative Example 1
In Example 1, it implemented similarly except not using copper foil.
比較例２
実施例１において、銅箔の代わりに２００ｇ／ｍ２のラテックス含浸紙を用いた以外は同様に実施した。
Comparative Example 2
In Example 1, it implemented similarly except having used 200 g / m < 2 > latex impregnated paper instead of copper foil.
比較例３
実施例２において、厚さ５０μｍのアルミ箔の代わりに、厚さ１０μｍのアルミ箔を用いた以外は同様に実施した。
Comparative Example 3
In Example 2, it implemented similarly except having used the 10-micrometer-thick aluminum foil instead of the 50-micrometer-thick aluminum foil.
評価結果を表１に示す。
試験方法は以下の通りとした。
不燃性：ＩＳＯ５６６０準拠したコーンカロリーメーターによる２０分試験の発熱性試験・評価方法ににおいて総発熱量を測定した。
可撓性：３５０Ｒのコンクリート製の丸柱に巻きつけ破損しないものを○、破損したものを×とした。
密着性：熱圧成形品の木口面からカッターを入れ層間で剥離が生じるかどうかを確認し、端部が５ｍｍ程度剥離して破損するものを○、全く剥離しないものを◎とした。
The test method was as follows.
Nonflammability: The total calorific value was measured in the exothermic test / evaluation method of a 20-minute test using a cone calorimeter in accordance with ISO 5660.
Flexibility: The case where it was wound around a 350R concrete round pillar and was not damaged was rated as "◯", and the damaged one was marked as "X".
Adhesiveness: A cutter was inserted from the mouth end of the hot-press molded product to confirm whether or not peeling occurred between the layers.
２ プリプレグ
３ メラミン樹脂含浸化粧紙
６ 銅箔
９ 可撓性不燃化粧板
2 Prepreg 3 Melamine resin impregnated decorative paper 6 Copper foil 9 Flexible incombustible decorative board
Claims (7)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004215885A JP4396893B2 (en) | 2004-07-23 | 2004-07-23 | Flexible incombustible decorative board |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004215885A JP4396893B2 (en) | 2004-07-23 | 2004-07-23 | Flexible incombustible decorative board |
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| Publication Number | Publication Date |
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| JP2006035507A true JP2006035507A (en) | 2006-02-09 |
| JP2006035507A5 JP2006035507A5 (en) | 2007-05-10 |
| JP4396893B2 JP4396893B2 (en) | 2010-01-13 |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013180414A (en) * | 2012-02-29 | 2013-09-12 | Sumitomo Bakelite Co Ltd | Manufacturing method of decorative panel |
| JP2013199003A (en) * | 2012-03-23 | 2013-10-03 | Sumitomo Bakelite Co Ltd | Incombustible decorative panel |
| JP2016144950A (en) * | 2016-05-16 | 2016-08-12 | 住友ベークライト株式会社 | Incombustible decorative panel |
| JP2019206153A (en) * | 2018-05-30 | 2019-12-05 | 旭化成株式会社 | Resin-containing multilayer structure |
-
2004
- 2004-07-23 JP JP2004215885A patent/JP4396893B2/en active Active
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013180414A (en) * | 2012-02-29 | 2013-09-12 | Sumitomo Bakelite Co Ltd | Manufacturing method of decorative panel |
| JP2013199003A (en) * | 2012-03-23 | 2013-10-03 | Sumitomo Bakelite Co Ltd | Incombustible decorative panel |
| JP2016144950A (en) * | 2016-05-16 | 2016-08-12 | 住友ベークライト株式会社 | Incombustible decorative panel |
| JP2019206153A (en) * | 2018-05-30 | 2019-12-05 | 旭化成株式会社 | Resin-containing multilayer structure |
Also Published As
| Publication number | Publication date |
|---|---|
| JP4396893B2 (en) | 2010-01-13 |
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